IPS enters into a beautiful AirSpeed HC partnership with a cosmetics supplier

Pregis and IPS Packaging approached the customer to see if they would consider a foam-in-place (FIP) alternative in its distribution center’s repacking area. The customer had been using Sealed Air’s Ultralite low-density foam in conjunction with the
Instapak FIP delivery system to protect its high-end skin, body care, and fragrance products. However, what started off as a review of one aspect of the packing operation, turned into a full-blown survey of the entire distribution center: products, applications, and operations.

This included three separate packaging areas:

  1. Repacking: The first production area put to the test. The HC system was trialed against Sealed Air’s 3/16 inch bubble wrap. Upon a close review, the customer discovered they were using so much bubble that they could get better, more cost-effective
    performance by switching to medium Hybrid Cushioning. Inventory space and labor were minimized because it was no longer necessary to drag bubble rolls across the plant floor to the repacking area. Another compelling component of the conversion was Renew’s formulation which enabled the company to promote its environmental benefits to its consumers.
  2. Internet Fulfillment Orders: The customer was using Sealed Air’s Korrvu suspension pack (a structure which combines corrugated and film to suspend and immobilize the product). They had been experiencing multiple problems with this pack: the components take up a fair amount of warehouse space; it’s expensive and the damage rate was too high. To make the HC/Renew solution even more efficient and viable, autobins with sensors were installed to automatically trigger the HC unit to produce more cushioning material when a low level is reached. By placing the autobins in front of each HC unit, the need to rewind and manually transfer bundles is eliminated.
  3. Inline Packing: All products that come down the conveyor belt were previously being packed with Instapak FIP. By moving to a complete change over the AirSpeed HC system, the customer was able to free up floor space previously used to store the chemical drums and avoid questions regarding foam’s environmental impact.

The end result was total replacement of Sealed Air’s products and equipment with AirSpeed systems and materials because they were able to improve the customers’:

  • Protective Packaging Solution
  • Operations
  • Total Cost-In-Use

Total Packaging Cost Summary

  • Material = significant reduction in plastic resin when switching to HC Renew
  • Space = Increase in work space due to the elimination of bulky bubble rolls
  • Labor = Reduction in labor due to lack of movement of bulky, cumbersome bubble rolls
  • Damage = Complete Reduction in Damage to 0%